Rockwell Automation CS300 User Manual

Trusted

PD-8162

Trusted

CS300 Bridge Module

Introduction

The CS300 Bridge Module presents a new opportunity to combine the CS300 I/O structure with the latest processing and communications features of Trusted

Combining the two products will enable CS300 users to benefit from features such as 3-3-2-0 Processor fault tolerance, IEC 1131 programming suite, Ethernet networks, OPC, Ethernet peer to peer and remote diagnostics. The CS300 Bridge Module replaces the CS300 ICCB in the CS300 Primary chassis.

Any system using the CS300 Bridge Module and Trusted Expanders and I/O modules forming a Hybrid system. To the Trusted and CS300 chassis appear in the same system map. All systems using Trusted can be seamlessly integrated together.

TMR Processor can also include TrustedTM

TMR Processor, the TrustedTM

TMR Processors

Upgrade Features

• Triple Modular Redundant (TMR), fault tolerant (3-3-2-0) operation

• Dedicated hardware and software test regimes which provide very fast fault

recognition and response times

• Automatic fault handling without nuisance alarming

• Hot replacement, self-configuration.

• Interfaces to Trusted

• Front panel indicators that show module health data transmission status

• TÜV certification and IEC61508 SIL3

TMR Expander Bus

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TrustedTM CS300 Bridge Module

Issue Record

Issue

umber Date Revised by Technical CheckAuthorised by Modification

1 Apr 08 A Holgate Nick Owens Pete Stock Initial Issue

2 Feb 10 A Holgate Nick Owens Pete Stock TC-322 details

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TrustedTM CS300 Bridge Module

Table of Contents

1. Description ...................................................................................................................................7

1.1. Overview......................................................................................................................................7

1.2. Power Distribution........................................................................................................................8

1.3. Communication Busses...............................................................................................................8

1.3.1. The TrustedTM to CS300 Primary Chassis...................................................................................8

1.3.2. Inter-Module Link (IML)................................................................................................................8

1.4. Function .......................................................................................................................................8

2. Installation....................................................................................................................................9

2.1. Module .........................................................................................................................................9

2.2. TC-322-02 Interface Cable assembly........................................................................................10

2.3. Module Configuration.................................................................................................................11

3. Application .................................................................................................................................13

3.1. System Configuration.................................................................................................................13

3.2. Board definitions........................................................................................................................17

3.3. Module – 8162 (Bridge Module).................................................................................................18

3.4. Module – bic (bus interface controller).......................................................................................19

3.5. Module – pi632 / pi732 (analogue input module).......................................................................20

3.6. Module – pi641 / pi741 (analogue output module).....................................................................21

3.7. Module – pi616_5 / pi616_9 / pi716 / pi717 (digital input module).............................................23

3.8. Module – pi626 / pi726 (digital output module)..........................................................................24

3.9. Module – pi627 / pi727 / pi627_fs / pi727_fs (digital output module).........................................26

3.10. Module – dmx_m (de-multiplexed display driver) ......................................................................28

3.11. Module – dmx_o (de-multiplexed display driver card) ...............................................................29

4. Operation ...................................................................................................................................30

4.1. Front Panel Indicators and Controls ..........................................................................................31

4.1.1. Tx & Rx Indicators .....................................................................................................................31

4.1.2. Health Indicator..........................................................................................................................31

4.1.3. On-Line Indicator and Switch.....................................................................................................31

5. Fault Finding and Maintenance..................................................................................................32

6. Specifications.............................................................................................................................33

Figures

Figure 1 Block Diagram showing interface between TrustedTM system and CS300 I/O ..........................7

Figure 2 8162 Bridge Module ...................................................................................................................9

Figure 3 TC-322-02 Interface Cable assembly.......................................................................................10

Figure 4 CS300 main chassis rear view .................................................................................................10

Figure 5 TrustedTM controller chassis rear view .....................................................................................11

Figure 6 CS300 Chassis Backplane.......................................................................................................11

Figure 7 TrustedTM Processor Chassis with Expander Interface ............................................................13

Figure 8 Insert New Chassis...................................................................................................................13

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TrustedTM CS300 Bridge Module

Figure 9 CS300 Main Chassis................................................................................................................14

Figure 10 Chassis Connection................................................................................................................14

Figure 11 Connected Chassis ................................................................................................................14

Figure 12 Jumper Setting .......................................................................................................................15

Figure 13 BIC Chassis Addressing.........................................................................................................15

Figure 14 CS300 Modules......................................................................................................................16

Figure 15 Module Options ......................................................................................................................16

Figure 16 Front Panel Layout .................................................................................................................30

Tab le s

Table 1 Bridge Module Associated Equipment.........................................................................................6

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TrustedTM CS300 Bridge Module

Precautionary Information

WARNING

Warning notices call attention to the use of materials, processes, methods, procedures or limits which

ust be followed precisely to avoid personal injury or death.

CAUTION

Caution notices call attention to methods and procedures which must be followed to avoid damage to the equipment.

Notes: Notes highlight procedures and contain information to assist the user in the understanding of the

information contained in this document

Warning

RADIO FREQUENCY INTERFERENCE

Most electronic equipment is influenced by Radio Frequency Interference (RFI). Caution should be exercised with regard to the use of portable communications equipment around such equipment. Signs should be posted in the vicinity of the equipment cautioning against the use of portable communications equipment.

MAINTENANCE

Maintenance must be performed only by qualified personnel, otherwise personal injury, death, or damage to the system may be caused.

Caution

HANDLING

Under no circumstances should the module housing be removed.

Associated Documents

Product Descriptions (PD) provide product specific information. The Safety Manual contains the recommended safety requirements for the safety system design. The PD-T8082 – Toolset Suite provides specific guidance on system configuration and application

generation. The Operator and Maintenance Manual contains general guidelines on maintenance and diagnostic

procedures.

For technical support email: support@icstriplex.com

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TrustedTM CS300 Bridge Module

Associated Equipment

Part Number Product Name Description

Adds equipment definitions for CS300 modules

T8043 CS300 Toolset Library

CS300/SC300E Interface Cable

TC-322-02

TC-324-02

Assembly CS300 Interface Cable

Connector Card

Table 1 Bridge Module Associated Equipment

to the Trusted To connect between Trusted

Interface Adaptor and CS300 Controller Chassis To attach TC-322-02 cable to CS300 Controller

Chassis

Toolset

Expander

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TrustedTM CS300 Bridge Module

Module

Bridge Module (A)

Backplane

1. Description

1.1. Overview

The CS300 Bridge Module enables connection between a CS300 I/O sub system and the TrustedTM TMR Processor. Three CS300 Bridge modules replace the three ICCB modules in a CS300 primary chassis.

The Bridge module has a fast serial ("Hotlink") interface that transfers command and response packets between the two product families via the Trusted Programmable Gate Array (FPGA) for decoding instructions from the Trusted accessing the specified CS300 I/O module and returning any data requested.

Command data received by the three Bridge modules and responses to the Trusted are synchronised in accordance with the Lock Step operational characteristics of the Trusted Expander Bus. For this reason, the three bridge modules share their data and arrange their response packets in the same order for simultaneous transmission. The clock signal received from the Expander Bus is used to ensure that data from all three Bridge modules is transmitted on the same clock edge.

The Trusted

TMR processor stores and executes the application program, scans and updates the CS300 I/O modules and detects system faults. Each of the three slices of the TMR Processor executes the application program independently, but in lock-step synchronisation with the other two.

All CS300 I/O actions are executed by polling only. This means that all CS300 I/O modules are supported, with the exception of Serial I/O modules (which generate interrupts). All communications to workstations and DCS systems are enabled through the Trusted

(C)

Expansion Bus (TC-322-02 Cable)

Expander Bus. The module uses a Field

Communications Interfaces.

(TC-324-02 Board)

Bridge Module (C)

TMR processor,

TMR Processor

Inter Module

Link

(B)

(A)

FCR A

Trusted

Expander

Interface

Trusted™

Main Chassis

FCR A

Bridge Module (B)

hotlin k

receiver

hotlin k

transmitter

CS30 0

Main Chassis

FPGA

Figure 1 Block Diagram showing interface between TrustedTM system and CS300 I/O

CS300

to CS300 I/O Modules

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TrustedTM CS300 Bridge Module

1.2. Power Distribution

Each of the Bridge modules is powered from triple redundant PSUs (situated in a separate chassis) that support the main I/O chassis with 5V, 12V & +/-20Vdc supplies and up to three CS300 extension chassis with 12V and +/-20Vdc only.

1.3. Communication Busses

1.3.1. The TrustedTM to CS300 Primary Chassis

Communication between the TrustedTM Expander Interface Module and the CS300 Primary Chassis is via one of a possible four or seven triplicated two-way interface cables. A single backplane connector card routes the individual links in the cable to the three Bridge modules. Data voting is provided at the Expander Module Interface to ensure that cable faults are detected.

The link handles the following triplicated signals: Data - Serial bi-directional bus. Control - Bus clocks, module-enables and bus direction control. Slot - Indicating the CS300 I/O slot position to the Bridge.

Expander Chassis ID - 4 bit Trusted

chassis address code.

1.3.2. Inter-Module Link (IML)

When returning data for TrustedTM Read requests, I/O Module data received by each Bridge module is shared with the other two using the serial IML via the backplane. The three sets of data are then arranged sequentially into the response packet for Trusted requests.

. The IML is not used during Write

1.4. Function

When an I/O access is to be performed, the TrustedTM TMR Processor issues a command packet to an Expander Interface Module. The Expander Interface decodes the chassis address and transmits the packet through an Expander bus to receivers in the 8162 Bridge modules.

For short distances of a few metres, a twisted-pair copper cable is used, whilst on longer runs the copper cable is connected to three T8312 fibre optic units at each end of three pairs (Tx and Rx) of fibre optic cable. The Bridge modules, receiving the command signals, decode the packet.

The Bridge modules then implement the read or write access on the CS300 I/O module selected and return a response packet via the serial expander bus. The packet will contain both data and diagnostic information.

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TrustedTM CS300 Bridge Module

2. Installation

2.1. Module

Each of the three Bridge modules replaces one of the CS300 ICCB modules. Figure 2 shows the module. The replacement must be carried out with the system offline.

The modules consist of a single PCB assembly.

Figure 2 8162 Bridge Module

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TrustedTM CS300 Bridge Module

2.2. TC-322-02 Interface Cable assembly

The interface cable connects from the TrustedTM Interface Adaptor T8312 to an identical 12 way socket on the interface cable connector card.

Figure 3 TC-322-02 Interface Cable assembly

Figure 4 CS300 main chassis rear view

Figure 4 shows the interface cable connector card (top left) fitted to the rear of the CS300 controller chassis which is connected to the Trusted

Expander Interface adaptor via the TC322-02 interface

cable (braided cable at top left). Connectors J1-3 on the TC-324-02 card plug into the three 26-way headers on the CS300 backplane.

The expander cable TC-322-02 from the Trusted

Expander Interface plugs into 12-way socket J4.

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TrustedTM CS300 Bridge Module

Figure 5 TrustedTM controller chassis rear view

Figure 5 shows a four socket version of the T8312 Expander Interface Adaptor with a TC-301-01 cable attached, which connects to a Trusted or seven connections available to individual Trusted

expander chassis. The Expander Interface Adapter has four

Expander chassis or to the CS300 controller

chassis using the TC-322-02 Interface Cable Assembly.

2.3. Module Configuration

The Bridge module requires minimum configuration, namely the setting of three sets of jumpers 0 to 3 to define the chassis address to Trusted shown here.

. These are situated on the CS300 chassis backplane as

Figure 6 CS300 Chassis Backplane

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